Folding boxes of the tray type



June 11, 1963 w. H. BANKS ETAL 3,093,290

I FOLDING BOXES OF THE TRAY TYPE Filed July 26, 1962 3 Sheets-Sheet 1INVENTORS. Wl/l/qm H. Ban/ 8 and Ric/lard C'. Poo/6 ATTORNEY June 11,1963 Filed July 26, 1962 W. H. BANKS ETAL FOLDING BOXES OF THE TRAY TYPE3 Sheets-Sheet 2 IN V EN TORS.

Wf/fiam H. Banks and klchard C. Poo/e June 11, 1963 w. H. BANKS ETAL3,093,290

FOLDING BOXES OF THE TRAY TYPE Filed July 26, 1962 s Sheets-Sheet 3 IN VEN TORS.

W/Y/fam H. Banks and BY R/chard C. POO/Q W %.W ATTORNEY United StatesPatent Ofifice 3,093,290 Patented June 11, 1963 3,093,290 FOLDING BOXESOF THE TRAY TYPE William H. Banks, Westport, Conn., and Richard C.Poole,

New Rochelle, N.Y., assignors to Atlas General Industries, Inc., NewYork, N.Y., a corporation of Massachusetts Filed July 26, 1962, Ser. No.212,605 4 Claims. (Cl. 229-34) This invention relates to improvements inthe construction of folding boxes of the tray type suited for gluelessassembly on automatic high speed box forming machinery from a singleblank and particularly designed for easy insention of merchandise to besupported and locked securely in cradled position on internal panels ofthe tray. The internal panels provide a centered eye catching display ofthe merchandise and thus serve an aesthetic function in addition totheir mechanical supporting and locking function.

Where merchandise must be securely locked in a tray and must beprotected against damage, particularly when trays are stacked, problemsarise with articles of inferior strength, for example collapsible tubes,as such articles must not be distorted by the force required to lockthem in the tray, yet the lock must be sufiiciently secure to retain thearticles in the tray during the jarring incidental to transport, andeven retain the articles when the package is dropped accidentally.

This invention provides a tray comprising an internal panel structurewhich is relatively easily deflectable for ready insertion of thearticle to be packaged, but offers far greater resistance to the removalof the article. The panel structure is so designed as to support thepackaged article in a cushioned position, out of contact with theoutside walls.

Trays incorporating the present invention may be assembled from singleblanks finished on one side only, for

example by imprinting, as only one side is exposed in the assembledtray.

These and various other objects, features and advantages of theinvention will appear more fully from the detailed description whichfollows, accompanied by drawings showing, for the purpose ofillustration, a preferred embodiment of the invention. The inventionalso resides in certain new and Original features of construction andcombination of elements hereinafter set forth and claimed.

Although the characteristic features of this invention which arebelieved to be novel will be particularly pointed out in the claimsappended hereto, the invention itself, its objects and advantages, andthe manner in which it may be carried out may be better understood byreferring to the following description taken in connection with theaccompanying drawings forming a part of it in which:

FIG. 1 shows, in plan view, a typical blank from which a tray embodyingthe invention may be formed;

FIGS. 2 and 3 are perspective views of successive stages of assembly ofthe blank of FIG. 1 into tray form;

FIG. 4 is a perspective view of the assembled tray with a tube packagedtherein; and

FIG. 5 is -a vertical cross section of the structure of FIG. 4, thesection being taken in plane 5-5 in FIG. 4.

In the following description and in the claims various details will beidentified by specific names for convenience. The names, however, areintended to be generic in their application. Corresponding referencecharacters refer to corresponding parts in the several figures of thedrawings.

The drawings accompanying, and forming part of, this specificationdisclose certain specific details of construction for the purpose ofexplanation of broader aspects of the invention, but it is understoodthat structural details may be modified in various respects withoutdeparture from the principles of the invention and that the inventionmay be incorporated in other structural forms than specifically shown.

The blank A shown in FIG. 1 may be cut and scored in multiple fromsheets or rolls of foldable board on conventional cutting and creasingmachines. The blank comprises a bottom panel 11 to the sides of whichside wall panels 12 and 13 are articulated along side fold lines 14 and15. End wall panels 16 and 17 are articulated to the ends of the bottompanel 11 along end fold lines 18 and 19.

Corner flaps 20, 21, 22 and 23 extend laterally from the side wallpanels along corner fold lines 24, 2.5, 26 and 27.

Inner side panels 28 and 29 are articulated to the side wall panels 12and 13 along top side fold lines 30 and 31. The inner side panels are oftapered shape, as their lateral edges 32, 33 and 34, 35 converge forreasons which will become more apparent as the description proceeds.Lateral lock tabs 36, '37, 38 and 39 are provided which project beyondthe converging edges 32, 33, 34 and 35, respectively. The length L ofthe inner side panels exceeds the corresponding dimension H of the sidewall panels, H being the height of the tray formed from the blank A.

End liner panels 40, 41 are articulated to the ends of the end wallpanels 16 and 17 along top end fold lines 42, 43. The length L of theend liner panels 40 and 41 exceeds the height H of the end panels 16 and17.

Base panels 44, 45 are articulated to the end liner panels along foldlines 46 and 47. Internal cuts 48 and 49 extending from fold lines 46and 47 form tongues 50 and 51 on the respective base panels 44 and 45.The tongues extend beyond the fold lines 46, 47 and comprise terminalabutment edges 52, 53 for abutting the end wall panels 16, 17 in theassembled tray, as will later be seen.

The internal cut 48 has the shape of an inverted flat U in the assembledtray, and the bight portion, which also forms the abutment edge, issubstantially straight for engaging a corresponding fiat portion of thearticle to be packaged, for example the flat seal seam of a collapsibletube.

The internal cut 49 comprises a central arcuate portion adapted, forexample, to engage the screw cap end of a tube.

The assembly or folding of the blank A into the form of a tray A (FIG.4) may be accomplished by an automatic plunger and die type box formingmachine in which a plunger first drives the blank into a folding die tofold the blank into the shape shown in FIG. 2. Thereafter the plungerwithdraws and folding elements fold the end panel assembly (FIG. 3andthereafter the side panel assembly to the inside of the tray, therebycompleting and locking the tray (FIG. 4). Merchandise may then beinserted into the tray to assume a locked position as represented inFIG. 5.

Considering the assembly operations in greater detail, the corner flaps20, 21, 22 and 23 are first folded into angular position with respect tothe wall panels 12 and 13, the wall panels 12 and 13 are then foldedupright with respect to the bottom panel 11 and the end panels 16 and 17are folded over the corner flaps (FIG. 2).

The end liner panels 40 and 41 are then folded into the tray interior,which operation causes the base panels 44 and 45 to assume a positionflat upon the base panel 11 with edges 52, 53 in edge-to-panel abutmentwith the tray ends, more particularly the corner flaps, as shown in FIG.3. The corner flaps thus are enclosed in hollow end spaces of the trayof substantially triangular cross section, as clearly seen in FIG. 3.

The inner side panels 28, 29 are then infolded until their tabs 36, 37,38 and 39 snap into the apertures formed in the end liner panels 40, 41by the internal cuts 48 and 49. In that position the lateral edges 32,33, 34 and 35 of the inner side panels 28, 29 assume an edge-tosurfaceabutting position with respect to the slanted end liner panels 40 and 41and stiffen them against upward flexing.

Merchandise, represented in the illustrated example by a collapsibletube 54 having a screw cap 55 and a seal seam end 56, is readilyinserted into the tray by slight downward pressure. The slanted innerside and end wall structures center the article automatically and theend liner panels deflect readily to permit the screw cap 55 and the sealseam 56 to snap under the retaining edges 48 and 49.

The inner side panels 28 and 29 also flex readily, and thereafterprovide a cushioning cradle-type support for the tube 54.

The panels 40 and 41 offer much higher resistance to a force tending towithdraw the tube from its locked position, as the panels 40 and 41 arestifiened by the abutting tapered side edges 32, 33, 34 and 35 of theinner side panels 28 and 29.

Obviously the configuration of the article supporting panels andinternal cuts 48, 49 may be altered to fit merchandise of other shapes,the collapsible tube being shown here solely as a representation of anarticle of inherently low strength.

What is claimed is:

l. A tray of foldable sheet material comprising, in combination, abottom panel; a pair of side panels articulated to opposite sides of thebottom panel; a pair of end panels articulated to opposite ends of thebottom panel; an end liner panel articulated to the top of each of theend panels and folded over the end panel on the inside of the tray; abase panel articulated to each of the end liner panels along a base foldline disposed to either side of the tongue hereafter recited, said endliner panel having a tongue cut therefrom by an internal cut extendingfrom said base fold line, said tongue lying substantially in the planeof said base panel, pointing toward the respective end panel, andcausing the said end liner panel to assume a slanted position, leaving ahollow space of substantially triangular cross section between endpanel, end liner panel, and bottom panel, into which space merchandiseto be packaged in the tray may be inserted, and an inner side panelarticulated to the top of each of the side panels, the inner side panelsbeing of a length greater than the height of the side panels and beingdisposed at a slant to the side panels and to the bottom panel, saidinner side panel having lateral lock tabs thereon for engaging theapertures formed in the said end liner panels by said internal cuts.

2. A tray of foldable sheet material comprising, in combination, abottom panel; a pair of side panels articulated to opposite sides of thebottom panel; a pair of end panels articulated to opposite ends of thebottom panel; an end liner panel articulated to the top of each of theend panels and folded over the end panel on the inside of the tray; abase panel articulated to each of the end liner panels along a base foldline disposed to either side of the tongue hereafter recited, said endliner panel having a tongue out therefrom by an internal cut extendingfrom said base fold line, said tongue lying substantially in the planeof said base panel, pointing toward the respective end panel, andcausing the said end liner panel to assume a slanted position, leaving ahollow space of substantially triangular cross section between endpanel, end liner panel, and bottom panel, into which space merchandiseto be packaged in the tray may be inserted, and an inner side panelarticulated to the top of each of the side panels, the inner side panelsbeing of a length greater than the height of the side panels and beingdisposed at a slant to the side panels and to the bottom panel, saidinner side panels having lateral edges'converging towards the ends ofthe inner side panels, said converging lateral edges lying inedge-to-surface engagement with said slanted end liner panels, andhaving lateral lock tabs thereon in substantial register with theapertures formed in the end liner panels by said internal cuts.

3. A tray of foldable sheet material for packaging a collapsible tube ofthe type having a screw cap at one end and a flat seal seam at the otherend, the tray comprising, in combination, a bottom panel; a pair of sidepanels articulated to opposite sides of the bottom panel; a pair of endpanels articulated to opposite ends of the bottom panel; an end linerpanel articulated to the top of each of the end panels and folded overthe end panel on the inside of the tray; a base panel articulated toeach of the end liner panels along a base fold line, one of said endliner panels having a tongue cut therefrom by an internal cut ofinverted substantially flat bottomed U shape, considering the tray insetup condition, said tongue forming an extension of said base panelextending beyond said base fold line and causing, by abutment with therespective end panel, the end liner panel to assume a slanted position,leaving a hollow space of substantially triangular cross section intowhich the seal seam of a tube may be inserted, the other end liner panelhaving an internal cut therein of substantially semicircular shape toaccommodate the screw end of a tube, said last named internal cutremoving material from the body of said other end liner to form a tongueextension on the other base panel, said last named tongue extensioncausing, by abutment with the other end panel, the said other end linerpanel also to assume a slanted position and form a hollow space ofsubstantially triangular cross section into which the cap end of a tubemay be inserted; and an inner side panel articulated to the top of eachof the side panels, the inner side panels being of a length greater thanthe height of the side panels and being disposed at a slant to the sidepanels and to the bottom panel, said inner side panel having laterallock tabs thereon for engaging the apertures formed in the said endliner panels by said internal cuts.

4. A tray of foldable sheet material comprising, in combination, abottom panel; a pair of side wall panels articulated to opposite sidesof the bottom panel, a pair of end wall panels articulated to oppositeends of the bottom panel; an end liner panel articulated to the top ofeach of the end panels and folded over the end panel on the inside ofthe tray; 21 base panel articulated to each of the end liner panelsalong a base fold line disposed to either side of the tongue hereafterrecited, said end liner panel having a tongue out therefrom by aninternal cut extending from said base fold line, said base panel andsaid tongue lying flat on the inside of the bottom panel with the tonguepointing towards the respective end panel and maintaining the end linerpanel in a slanted position, leaving a hollow space of substantiallytriangular cross section between end wall panel, liner panel, and bottompanel; an inner side panel articulated to the top of each of the sidepanels, the inner side panels being of a length greater than the heightof the side wall panels and being disposed at a slant to the side wallpanels and to the bottom panel, said inner side panels having threebounding cut edges, including two converging lateral edges, for engagingthe end liner panels in edge-to-surface position, certain of said cutedges comprising projecting edge portions for locking the inner sidepanels in the unfolded position in which they are in edge-to-surfaceengagement with said end liner panels; and corner flaps articulated tothe ends of certain Wall panels and inserted into the triangular spaceof the adjacent walls at the respective tray corners.

References Cited in the file of this patent UNITED STATES PATENTSFrankenstein 'Feb. 23, 1954 Nernoede Aug. 2, 1955 Nemoede Nov. 22, 1955Stone Mar. 3, 1959 'Frisosky et a1 Apr. 11, 1961

1. A TRAY OF FOLDABLE SHEET MATERIAL COMPRISING, IN COMBINATION, ABOTTOM PANEL; A PAIR OF SIDE PANELS ARTICULATED TO OPPOSITE SIDES OF THEBOTTOM PANEL; A PAIR OF END PANELS ARTICULATED TO OPPOSITE ENDS OF THEBOTTOM PANEL; AN END LINER PANEL ARTICULATED TO THE TOP OF EACH OF THEEND PANELS AND FOLDED OVER THE END PANEL ON THE INSIDE OF THE TRAY; ABASE PANEL ARTICULATED TO EACH OF THE END LINER PANELS ALONG A BASE FOLDLINE DISPOSED TO EITHER SIDE OF THE TONGUE HEREAFTER RECITED, SAID ENDLINER PANEL HAVING A TONGUE CUT THEREFROM BY AN INTERNAL CUT EXTENDINGFROM SAID BASE FOLD LINE, SAID TONGUE LYING SUBSTANTIALLY IN THE PLANEOF SAID BASE PANEL, POINTING TOWARD THE RESPECTIVE END PANEL, ANDCAUSING THE SAID END LINER PANEL TO ASSUME A SLANTED POSITION, LEAVING AHOLLOW SPACE OF SUBSTANTIALLY TRIANGULAR CROSS SECTION BETWEEN ENDPANEL, END LINER PANEL, AND BOTTOM PANEL, INTO WHICH SPACE MERCHANDISETO BE PACKAGED IN THE TRAY MAY BE INSERTED, AND AN INNER SIDE PANELARTICULATED TO THE TOP OF EACH OF THE SIDE PANELS, THE INNER SIDE PANELSBEING OF A LENGTH GREATER THAN THE HEIGHT OF THE SIDE PANELS AND BEINGDISPOSED AT A SLANT TO THE SIDE PANELS AND TO THE BOTTOM PANEL, SAIDINNER SIDE PANEL HAVING LATERAL LOCK TABS THEREON FOR ENGAGING THEAPERTURES FORMED IN THE SAID END LINER PANELS BY SAID INTERNAL CUTS.